Preparation of Sulfide Solid-State Batteries and Battery Assembly Methods
Jul 24, 2025
In recent years, the rapid development of sulfide solid electrolytes—including Li₂S-SiS₂, Li₂S-B₂S₃, Li₂S-P₂S₅, Li(₁₀±₁)MP₂S₁₂(where M = Ge, Si, Sn, Al, or P), and Li₆PS₅X (where X = Cl, Br, I)—has, in particular, partially addressed the drawback of insufficient intrinsic conductivity in solid electrolytes. This progress is exemplified by thio-LISICON-structured sulfides such as Li₁₀GeP₂S₁₂(LGPS), which exhibit an extremely high room-temperature lithium-ion conductivity of 12 mS/cm, surpassing that of liquid electrolytes. Figure 1(a) shows an all-solid-state lithium battery using a cold-pressed pellet of Li₁₀Ge₂PS₁₂ceramic solid electrolyte powder with a room-temperature electrical conductivity exceeding 5 mS/cm, a LiCoO₂cathode material, a 99% (30Li₂S·70P₂S₅)·1% P₂O₅electrolyte as the anode-side modifier electrolyte, and metallic lithium as the anode. This battery can normally discharge and operate at room temperature to light up an LED lamp. A schematic diagram of the core component structure is shown in Figure 1(b), from which it can be seen that the cathode layer, inorganic solid electrolyte layer, and lithium foil are tightly bonded and pressed together in a mold. The preparation methods and processes of each component will be described in detail below. Figure 1: All-Solid-State Lithium Battery Based on Sulfide Solid Electrolyte 1 Preparation Method of the Cathode Sulfide solid electrolyte powder exhibits a Young's modulus of approximately 20 GPa, along with strong adhesion, high compressibility, and a tendency for plastic deformation. After cold pressing, it demonstrates low grain boundary resistance; thus, it is suitable for direct dry mixing with cathode powder during the preparation of the cathode layer [Fig. 2(a)]. During dry mixing, the conductive agent, sulfide solid electrolyte, and cathode material are simultaneously added to a mortar, followed by manual grinding, or mechanically mixed using a stirrer. It should be noted that the compatibility between different cathode materials and the electrolyte, the applicability of various conductive agents, and the suitability of different cathode coatings need to be evaluated under practical conditions. Figure 2: Preparation Method of the Cathode for All-Solid-State Lithium Batteries Based on Sulfide Solid Electrolytes For large-scale roll-to-roll (R2R) fabrication of sulfide batteries, the wet coating process [Fig. 2(b)] may be more suitable for scaling up. This is because polymer binders and solvents are required to prepare thin-film electrolyte and electrode layers with the mechanical properties needed for high-throughput R2R processes. Additionally, the presence of flexible polymers in the electrolyte/electrode can effectively buffer the stress and strain generated during repeated charge-discharge cycles, mitigating issues such as crack formation and particle detachment. However, the following considerations are necessary during preparation: ① The polymer binder should be di...
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